Method Of Inflatable Game Ball Panel Construction

ABSTRACT

An inflatable game ball and a method of constructing an inflatable game ball is described. Panel segments are formed from an outer panel portion and an inner panel portion having different sizes, with the inner panel portion being smaller than the outer panel portion. The inner panel portion and the outer panel portion are joined so that peripheral edges of the inner panel portion and the outer panel portion are aligned. Multiple panel segments are attached together to form a cover. Due to the differences in sizes between the inner panel portion and the outer panel portion, when an inflatable bladder within an interior of the cover is inflated to a fully inflated condition, variations in the dimensions of the ball caused by stretching of the cover may be reduced or minimized. In one embodiment, an alignment guide can assist with aligning the peripheral edges of the panel portions.

BACKGROUND

The present invention relates generally to inflatable game balls, andmore specifically, to a method of inflatable game ball panelconstruction using different sized panel layers.

Inflatable game balls, including basketballs, footballs, soccer balls,and volleyballs, are well known in the art and typically include anoutside cover with an inflatable bladder on the inside. Specificallywith respect to American footballs, the outside cover is formed ofmultiple panels made of natural leather or hide, synthetic leather,plastic, or fabric stitched or otherwise secured to one another. Theinflatable bladder is then filled with air to inflate the football.

When the inflatable bladder fills with air, the outside cover willtypically stretch to some degree to reach a fully inflated condition. Inthe case of footballs made of natural leather or hide, the outside covercan exhibit variations in the amount of stretching due to inherentdifferences in the degree or amount of stretch between different piecesof leather. As a result, two footballs having covers made of identicallysized pieces may have slightly different dimensions when fully inflatedto the same internal pressure.

Therefore, there exists a need in the art for a method of footballconstruction that can assist with providing a football having consistentdimensions when fully inflated.

SUMMARY

In one aspect, the invention provides a method of constructing aninflatable game ball, the method comprising: removing a plurality ofouter panel portions from a first material, each of the outer panelportions having a first shape and a first size; removing a plurality ofinner panel portions from a second material, each of the inner panelportions having the first shape and a second size, the second size beingsmaller than the first size; joining the plurality of outer panelportions to the plurality of inner panel portions along peripheral edgesto form a plurality of panel segments, each panel segment having aperipheral edge of one of the plurality of outer panel portions that isaligned with the peripheral edge of one of the plurality of inner panelportions; and attaching the plurality of panel segments together alongthe aligned peripheral edges to form a cover of the inflatable gameball.

In another aspect, the invention provides a method of constructing aninflatable game ball, the method comprising: providing a first outerpanel portion removed from a first material, the first outer panelportion having a first shape and a first size, providing a first innerpanel portion removed from a second material, the first inner panelportion having the first shape and a second size, the second size beingsmaller than the first size; providing an alignment guide having thefirst shape and associated with an interior dimension that issubstantially similar to the second size; placing the first inner panelportion into the interior of the alignment guide such that a peripheraledge of the first inner panel portion is adjacent to an inner surface ofthe alignment guide; placing the first outer panel portion into theinterior of the alignment guide such that a peripheral edge of the firstouter panel portion is disposed against the inner surface of thealignment guide; joining the first inner panel portion to the firstouter panel portion along peripheral edges to form a panel segment, thepanel segment having the peripheral edge of the first outer panelportion aligned with the peripheral edge of the first inner panelportion; and attaching together a plurality of panel segments along thealigned peripheral edges to form a cover of the inflatable game ball.

In another aspect, the invention provides an inflatable game ballcomprising: a cover, the cover comprising a plurality of panel segmentsattached along peripheral edges; and an inflatable bladder disposedwithin an interior of the cover, the inflatable bladder being associatedwith a deflated condition and a fully inflated condition; wherein eachpanel segment comprises: a first outer panel portion having a firstshape and a first size; a first inner panel portion having the firstshape and a second size, the second size being smaller than the firstsize; and wherein the first outer panel portion is joined with the firstinner panel portion such that a peripheral edge of the first outer panelportion is aligned with a peripheral edge of the first inner panelportion.

Other systems, methods, features and advantages of the invention willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the invention, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of an exemplary embodiment of a process ofconstructing an inflatable game ball in the form of a football;

FIG. 2 is a schematic view of an exemplary embodiment of a process ofconstructing a football using panel layers having different sizes;

FIG. 3A is a top plan view of exemplary embodiments of panel layershaving different sizes for use in constructing a football;

FIG. 3B is a top plan view of exemplary embodiments of panel layershaving different sizes for use in constructing a football;

FIG. 4 is a schematic view of an exemplary embodiment of a panel layerfor use in constructing a football;

FIG. 5 is a schematic view of an exemplary embodiment of a process ofjoining panel layers for use in constructing a football;

FIG. 6 is a schematic view of an exemplary embodiments of a process ofjoining panel layers along corresponding peripheral edges;

FIG. 7 is a schematic view of an exemplary embodiment of a panel segmentfor a football;

FIG. 8 is a cross-section view of an exemplary embodiment of a panelsegment for a football;

FIG. 9 is an exploded view of an exemplary embodiment of an alignmentguide for use in constructing a football;

FIG. 10 is a schematic view of an exemplary embodiment of an alignmentguide and panel segment;

FIG. 11 is an exploded view of an exemplary embodiment of a football;

FIG. 12 is a schematic view of an exemplary embodiment of a process ofjoining multiple panel segments to form a cover for a football;

FIG. 13 is a schematic view of an exemplary embodiment of a footballformed of multiple panel segments;

FIG. 14 is a cross-section view of an exemplary embodiment of a footballillustrating panel layers and an inflatable bladder in the process ofbeing inflated;

FIG. 15 is a cross-section view of an exemplary embodiment of a footballillustrating panel layers and an inflatable bladder in a fully inflatedcondition;

FIG. 16 is a top plan view of exemplary embodiments of panel layershaving different sizes for use in constructing a soccer ball;

FIG. 17 is an exemplary embodiment of panel segments for a soccer ball;and

FIG. 18 is an exemplary embodiment of a soccer ball formed of multiplepanel segments.

DETAILED DESCRIPTION

The various embodiments described herein relate to an inflatable gameball, particularly, an inflatable game ball in the shape of a spheroidand/or a prolate spheroid. In an exemplary embodiment, a prolatespheroidal inflatable game ball may be pointed at the ends, for exampleas is typically used in American football. While the pointedness of aninflatable game ball typically used to play American football, includingfootballs approved for use in the NFL, NCAA, high school or otherleagues, causes it to differ from a true geometric prolate spheroid,such footballs are typically considered to be prolate spheroidal balls,and are encompassed by that term as used herein. In other embodiments,prolate spheroidal inflatable game balls may be configured with shapesthat correspond to balls used with other sports, including, but notlimited to rugby, Australian rules football, and other sports using aball having an oblong or elliptical spheroidal shape.

FIGS. 1-15 illustrate an exemplary embodiment of a process ofconstructing an inflatable game ball and an inflatable game ball in theform of a football made using the exemplary process. FIG. 1 illustratesan exemplary embodiment of materials for constructing a football. Whilethe exemplary process described herein is used for constructing afootball, similar principles may be applied to the construction of otherinflatable game balls, including footballs, soccer balls, basketballs,volleyballs, and other game balls having a cover and inflatable bladder.

In some embodiments, a cover for a football may be made of multipleindividual panel segments. In one embodiment, a cover for a football maybe made of four individual panel segments. In other embodiments,however, a larger or smaller number of panel segments may be used toform the cover. A cover may be made of a variety of materials,including, but not limited to natural leather or hide, syntheticleather, woven and non-woven fabrics, rubber, plastics, or any othermaterials known in the art. In some cases, different materials may beused for different portion of a cover.

In an exemplary embodiment, an outer layer for a cover of a football maybe made of an outer layer material 100. In this embodiment, outer layermaterial 100 is a natural leather or hide material having a texturedsurface 102. In other embodiments, outer layer material 100 may includesynthetic leather or other suitable materials for a cover, describedabove. In one embodiment, a first pattern 104 that corresponds to adesired shape and size of the panels forming the outer layer of thecover of the football may be provided on outer layer material 100.

In some embodiments, a cover of a football may further include an innerlayer or a backing layer that is associated with the outer layer of thecover. In an exemplary embodiment, an inner layer for a cover may bemade of an inner layer material 110. In this embodiment, inner layermaterial 110 is a woven or non-woven textile material, such as cotton,nylon or polyester, having a top surface 112. In other embodiments,inner layer material 110 may include canvas or other fabrics, rubber, orother suitable materials for a cover, described above. In oneembodiment, a second pattern 114 that corresponds to a desired shape andsize of the panels forming the inner layer or backing layer of the coverof the football may be provided on inner layer material 110.

In an exemplary embodiment, first pattern 104 associated with an outerpanel layer may be larger than second pattern 114 associated with aninner panel layer. As will be described in more detail below, a methodof football constructing using panel layers having different sizes canassist with providing footballs having more consistent dimensions whenfully inflated.

Referring now to FIG. 2, an exemplary embodiment of a process forforming a panel segment of a cover of a football is illustrated. In someembodiments, a first outer panel portion 200 may be an outer panel layerthat is removed from outer layer material 100 along first pattern 104.In one embodiment, first outer panel portion 200 may be associated witha pointed elliptical shape having a first length L1 in a longitudinaldirection between a first end 202 and a second end 204 along a majoraxis and a first width W1 in a lateral direction between a first side206 and a second side 208 along a minor axis. In some embodiments, afirst inner panel portion 210 may be an inner panel layer that issimilarly removed from inner layer material 110 along second pattern114. In one embodiment, first inner panel portion 210 may be associatedwith a pointed elliptical shape having a second length L2 in alongitudinal direction between a first end 212 and a second end 214along a major axis and a second width W2 in a lateral direction betweena first side 216 and a second side 218 along a minor axis.

In various embodiments, first outer panel portion 200 and/or first innerpanel portion 210 may be removed from outer layer material 100 and/orinner layer material 110 using any known method of removing materialalong a pattern, for example, by cutting or stamping.

In an exemplary embodiment, first length L1 associated with first outerpanel portion 200 may be larger than second length L2 associated withfirst inner panel portion 210. In some cases, first length L1 may beapproximately 2 mm to 8 mm larger than second length L2. In oneembodiment, first length L1 may be approximately 4 mm larger than secondlength L2. In other cases, first length L1 may be less than 2 mm largerthan second length L2 or may be more than 8 mm larger than second lengthL2. In a similar manner, first width W1 associated with first outerpanel portion 200 may be larger than second width W2 associated withfirst inner panel portion 210. In some cases, first width W1 may beapproximately 2 mm to 8 mm larger than second width W2. In oneembodiment, first width W1 may be approximately 4 mm larger than secondwidth W2. In other cases, first width W1 may be less than 2 mm largerthan second width W2 or may be more than 8 mm larger than second widthW2. In different embodiments, the difference in lengths and/or widthsbetween the panels may vary from 0 mm to 12 mm.

In some embodiments, the difference between the sizes of the respectivepanel layers may be substantially uniform around the perimeter of thepanel such that the difference between the lengths of the panels issubstantially similar to the difference between the widths of thepanels. In an exemplary embodiment, the difference between first lengthL1 and second length L2 may be substantially similar to the differencebetween first width W1 and second width W2. Referring now to FIG. 3A, atop plan view of first outer panel portion 200 and first inner panelportion 210 having different sizes is illustrated. As shown in thisembodiment, the difference in sizes between first outer panel portion200 and first inner panel portion 210 is substantially uniform aroundthe entire perimeter of the panels. In this embodiment, a first distanceD1 separates the peripheral edges of first outer panel portion 200 andfirst inner panel portion 210 at both first side 206 of first outerpanel portion 200 and first side 216 of first inner panel portion 210and at first end 202 of first outer panel portion 200 and first end 212of first inner panel portion 210. Additionally, in this embodiment,first distance D1 separates the peripheral edges of other portions offirst outer panel portion 200 and first inner panel portion 210 betweenfirst side 206, 216 and first end 202, 212, as well as other portionsaround the perimeter of the two panel portions.

In some embodiments, first distance D1 may be substantially equal toapproximately half the difference between first length L1 and secondlength L2 and/or first width W1 and second width W2. Accordingly, insome cases, first distance D1 may be approximately from 1 mm to 4 mm. Inone embodiment, first distance D1 may be approximately 2 mm. In othercases, first distance D1 may be less than 1 mm or may be more than 4 mm.

In some embodiments, the difference between the sizes of the respectivepanel layers may vary at different portions around the perimeter of thepanels such that the difference between the lengths of the panels isdifferent than the difference between the widths of the panels. In anexemplary embodiment, the difference between first length L1 and secondlength L2 may be different than the difference between first width W1and second width W2. Referring now to FIG. 3B, a top plan view of firstouter panel portion 200 and first inner panel portion 210 havingdifferent sizes is illustrated. As shown in this embodiment, thedifference in sizes between first outer panel portion 200 and firstinner panel portion 210 varies at different portions around theperimeter of the panels. In this embodiment, a difference in widthdistance DW separates the peripheral edges of first outer panel portion200 and first inner panel portion 210 at both first side 206 of firstouter panel portion 200 and first side 216 of first inner panel portion210. In contrast, a difference in length distance DL separates theperipheral edges of first outer panel portion 200 and first inner panelportion 210 at first end 202 of first outer panel portion 200 and firstend 212 of first inner panel portion 210.

In some embodiments, difference in width distance DW may be differentthan difference in length distance DL. In an exemplary embodiment,difference in width distance DW may be larger than difference in lengthdistance DL. In one embodiment, first outer panel portion 200 may beapproximately 2 mm larger in length than first inner panel portion 210,corresponding to difference in length distance DL of approximately 1 mmat each of first end 202, 212 and second end 204, 214 and first outerpanel portion 200 may be approximately 4.5 mm larger in width than firstinner panel portion 210, corresponding to a difference in width distanceDW of approximately 2.25 mm at each of first side 206, 216 and secondside 208, 218. With this arrangement, the proportion of difference inlength distance DL to difference in width distance DW may providesufficient stretch along each of the longitudinal and lateral directionsof the cover of the football when in the fully inflated condition suchthat variations in dimensions of the football are minimized or reduced.

In some cases, difference in width distance DW may be approximately from2 mm to 2.5 mm and difference in length distance DL may be approximatelyfrom 0.75 mm to 1.5 mm. In other cases, difference in width distance DWmay be less than 2 mm or may be more than 2.5 mm and difference inlength distance DL may be less than 0.75 mm or may be more than 1.5 mm.Additionally, in this embodiment, portions of the peripheral edges offirst outer panel portion 200 and first inner panel portion 210 betweenfirst side 206, 216 and first end 202, 212, may vary in a substantiallycontinuous manner from difference in width distance DW at first side206, 216 and different than difference in length distance DL at firstend 202, 212. The remaining portions of the peripheral edges disposedaround the perimeter of first outer panel portion 200 and first innerpanel portion 210 may vary in a substantially similar manner.

Accordingly, by varying the difference in sizes along differentdirections of the panel layers, the amount of stretch along eachdirection of the constructed football may be limited or restricted bydifferent amounts. With this arrangement, a panel segment may have alarger difference between the respective widths of the panel layers thanthe difference between the respective lengths of the panel layers toaccount for a larger amount of stretch that occurs along the width ofthe panels in the lateral direction than the amount of stretch thatoccurs along the length of the panels in the longitudinal direction whenan inflatable bladder is in a fully inflated condition.

FIGS. 4 through 7 illustrate an exemplary embodiment of a process ofassembling a single panel segment for use in constructing a football. Itshould be understood that the process may be repeated to produceadditional panel segments that will be combined to form the cover of thefootball, as will be described below. Referring now to FIG. 4, in someembodiments, first inner panel portion 210 may be joined with firstouter panel portion 200. In one embodiment, first inner panel portion210 may have a band of adhesive 300 disposed along a peripheral edge 302of first inner panel portion 210. Adhesive 300 may be a glue,double-sided tape, or other bonding agent. In an exemplary embodiment,adhesive 300 may extend substantially around the entire perimeter offirst inner panel portion 210 along peripheral edge 302. In thisembodiment, adhesive 300 may be applied from peripheral edge 302 to aninner periphery 304 located approximately a second distance D2 fromperipheral edge 302. In one embodiment, second distance D2 may beapproximately 2 mm to 5 mm. In other embodiments, second distance D2 maybe larger or smaller.

Adhesive 300 may be any type of adhesive or bonding agent that isconfigured to hold or otherwise associate first inner panel portion 210and first outer panel portion 200 together. In some cases, adhesive 300may be sufficiently strong so as to temporary associate together and tohold the respective panel portions in place so that the panel portionsmay be joined using a permanent attachment mechanism, for example,stitching or bonding. In other cases, first inner panel portion 210 maybe joined to first outer panel portion 200 using other known attachmentmechanisms, including, but not limited to bonding, welding, stitching orother temporary or permanent attachment mechanisms.

FIG. 5 illustrates first outer panel portion 200 aligned over firstinner panel portion 210. First outer panel portion includes an exteriorsurface 500 and an interior surface 502. In this embodiment, exteriorsurface 500 includes a textured surface to assist with grippability ofthe cover of the constructed football. First inner panel portion 210includes a top surface 504 and a bottom surface (not visible). In thisembodiment, adhesive 300 is disposed on top surface 504 extending aroundperipheral edge 302. However, in some embodiments, first outer panelportion 200 may also have a substantially similar adhesive applied ontointerior surface 502 to assist with adhesion between first inner panelportion 210 and first outer panel portion 200.

In an exemplary embodiment, the separate panel portions may be arrangedsuch that interior surface 502 of first outer panel portion 200 isoriented towards top surface 504 of first inner panel portion 210. In anexemplary embodiment, a peripheral edge 506 of first outer panel portion200 may be brought together with peripheral edge 302 of first innerpanel portion 200.

FIGS. 6 and 7 illustrate an exemplary embodiment of forming a firstpanel segment 600 by joining first outer panel portion 200 and firstinner panel portion 210. As shown in FIG. 6, second end 204 of firstouter panel portion 200 is joined at second end 214 of first inner panelportion 210 and peripheral edge 506 is joined with peripheral edge 302extending along the perimeter of first inner panel portion 210 towardsfirst end 212. Referring now to FIG. 7, in an exemplary embodiment,peripheral edge 506 of first outer panel portion 200 and peripheral edge302 of first inner panel portion 210 are joined by adhesive 300 alongentire perimeter of first inner panel portion 210. Together, first outerpanel portion 200 and first inner panel portion 210 form first panelsegment 600. Adhesive 300 holds peripheral edge 506 in alignment withperipheral edge 302. With this configuration, the smaller size of firstinner panel portion 210 causes first outer panel portion 200 to bulgeoutward causing exterior surface 500 to have a substantially convexsurface 700. In other embodiments, other attachment mechanisms may besimilarly used to join peripheral edge 506 of first outer panel portion200 and peripheral edge 302 of first inner panel portion 210 along therespective perimeters.

FIG. 8 shows a cross-section view of first panel segment 600. In thisembodiment, peripheral edge 506 and peripheral edge 302 aresubstantially aligned so that both first outer panel portion 200 andfirst inner panel portion 210 have second width W2. However, becausefirst width W1 of first outer panel portion 200 is larger than secondwidth W2, first outer panel portion 200 bulges outward causing exteriorsurface 500 to have convex surface 700. In this embodiment, convexsurface 700 of first outer panel portion 200 bulges outward by a thirddistance D3 from first inner panel portion 210. In some embodiments,third distance D3 is approximately equal to the difference between firstwidth W1 and second width W2. In some cases, third distance D3 may befrom 2 mm to 8 mm. In one embodiment, third distance D3 may beapproximately 4 mm. In other cases, third distance D3 may be less than 2mm or may be more than 8 mm.

In some embodiments, the process described above for aligning peripheraledge 506 of first outer panel portion 200 and peripheral edge 302 offirst inner panel portion 210 may be assisted by using an alignmentguide. FIGS. 9 and 10 illustrate an exemplary embodiment of an alignmentguide 900 that may be provided to assist with the process of aligningthe peripheral edges of first outer panel portion 200 and first innerpanel portion 210. In some embodiments, alignment guide 900 may be a jigor mold that has interior dimensions that correspond to the dimensionsassociated with first inner panel portion 210.

In this embodiment, the interior dimensions of alignment guide 900correspond to second length L2 in a longitudinal direction between afirst end 902 and a second end 904 along a major axis and second widthW2 in a lateral direction between a first side 906 and a second side 908along a minor axis. In an exemplary embodiment, the interior dimensionsof alignment guide 900 correspond to second length L2 and second widthW2 associated with first inner panel portion 210, described above.

In some embodiments, alignment guide 900 may be made of a rigid orsemi-rigid material that is configured to hold a shape of the panelportions disposed with an interior 916 of alignment guide 900. In anexemplary embodiment, alignment guide 900 may include a wall 910 thatextends around the perimeter of alignment guide 900. Wall 910 mayinclude an outer surface 914 and an inner surface 912. In some cases,alignment guide 900 may include a releasable attachment mechanism, forexample, a band or clamp, so that wall 910 may be opened or closed torelease the completed panel segment from within interior 916 ofalignment guide.

In some embodiments, the process of FIGS. 4 through 7 may be performedusing alignment guide 900. In an exemplary embodiment, first inner panelportion 210 may be placed into interior 916 of alignment guide 900 suchthat peripheral edge 302 is substantially surrounded by inner surface912 of wall 910. Next, adhesive 300 may be applied to one or more of topsurface 504 of first inner panel portion 210 and/or interior surface 502of first outer panel portion 200. As shown in FIG. 9, first outer panelportion 200 has dimensions of first length L1 and first width W1 thatare larger than the interior dimensions of alignment guide 900.Accordingly, when first outer panel portion 200 is placed into interior916 of alignment guide 900 to join with first inner panel portion 210,inner surface 912 of wall 910 may serve as a guide to constrain movementof first outer panel portion 200, thereby keeping peripheral edge 302and peripheral edge 506 aligned so that adhesive 300 may set. In otherembodiments, inner surface 912 of wall 910 may similarly serve as aguide to constrain movement peripheral edge 506 of first outer panelportion 200 and peripheral edge 302 of first inner panel portion 210while other attachment mechanisms are used to join the panel portionsalong their respective perimeters. For example, in embodiments wherewelding is used, wall 910 may hold the respective edges in alignmentwhile an ultrasonic welder or other welding apparatus is used to joinperipheral edge 506 of first outer panel portion 200 and peripheral edge302 of first inner panel portion 210.

As shown in FIG. 10, in this embodiment, first inner panel portion 210and first outer panel portion 200 may be placed within interior 916 ofalignment guide 900 such that peripheral edge 302 and peripheral edge506 are bounded by inner surface 912 of wall 910. First panel segment600 may then be removed from alignment guide 900. In some embodiments,multiple panel segments substantially similar to first panel segment 600may be formed using a similar process, including with or withoutalignment guide 900.

Referring now to FIG. 11, an exploded view of a football constructedwith multiple panel segments around an inflatable bladder 1100 is shown.In some embodiments, multiple panel segments substantially similar tofirst panel segment 600 may be formed using the process described above.In an exemplary embodiment, the multiple panel segments may be joinedtogether to form a cover and be associated with inflatable bladder 1100to construct a football. In this embodiment, four panel segments areprovided to form the cover, including first panel segment 600, a secondpanel segment 602, a third panel segment 604, and a fourth panel segment606. Each of second panel segment 602, third panel segment 604, andfourth panel segment 606 may have a substantially similar constructionas first panel segment 600, including an outer panel portion and aninner panel portion having different sizes that are joined alongcorresponding peripheral edges.

In some embodiments, a cover for a football may include multiple panelsegments that are stitched, sewed or otherwise joined together alongrespective edges using adhesive, ultrasonic welding, bonding, or otherattachment mechanisms known in the art to form the cover. Typically, acover is formed inside-out, with the interior surface facing outwardsand the exterior surface facing inwards. A portion of the respectiveedges between a pair of adjacent panel segments is left unattached sothat an opening is provided to the interior of the inside-out cover. Thecover is then turned right-side out by pushing the cover through theopening so that the exterior surface is facing outwards and the interiorsurface is facing inwards. An inflatable bladder may then be insertedthrough the opening and inflated.

Referring now to FIG. 12, an exemplary embodiment of a cover 1200 of afootball is illustrated. In an exemplary embodiment, four panelsegments, including first panel segment 600, second panel segment 602,third panel segment 604, and fourth panel segment 606 may be joinedtogether to form cover 1200. In one embodiment, the panels are joined bystitching along the respective adjacent edges of each panel segment. Inan exemplary embodiment, the stitching joining the adjacent panelsegments is configured to pass through both the outer panel portion andthe inner panel portion of each panel segment at or near the adhesivelyattached peripheral edges.

In this embodiment, first panel segment 600 is stitched to third panelsegment 604 along a seam 1204. With this arrangement, the stitching ofseam 1204 is configured to pass through first outer panel portion 200,first inner panel portion 210, as well as a similar outer panel portionand inner panel portion associated with third panel segment 604. Each ofthe remaining panel segments may be similarly joined, such that thirdpanel segment 604 is stitched to fourth panel segment 606 along a seam1206 and fourth panel segment 606 is stitched to second panel segment602 (not shown in FIG. 12) along a seam 1208. Additionally, first panelsegment 600 may be stitched to portions of second panel segment 602along a seam 1202 that extends from each of a first end 1210 and asecond end 1212 of cover 1200. A portion of first panel segment 600 andsecond panel segment 602 may remain unattached to form an opening 1214.

In some embodiments, opening 1214 may be provided so that cover 1200 maybe turned right-side out through opening 1214. Additionally, opening1214 may further permit inflatable bladder 1100 to be inserted withincover 1200. In an exemplary embodiment, inflatable bladder 1100 may beinserted within cover 1200 in a deflated condition. Inflatable bladder1100 may be filled with air to a particular pressure level to a fullyinflated condition. A variety of pressure levels may be appropriate fora ball for any particular game. In some cases, a conventional inflationvalve (not shown) that permits the insertion of a typical needle (notshown) that may be connected to a bicycle pump or other suitable airpump (not shown) may be included to allow air to be introduced intoinflatable bladder 1100. This type of inflation valve may be positionedanywhere desirable or convenient on cover 1200 as a designer mightselect.

FIG. 13 illustrates an exemplary embodiment of a finished football 1300.The dimensions of football 1300 may be configured in accordance with therules and requirements of different agencies, including, but not limitedto the NFL, NCAA, high school or other leagues and/or agencies, whichrules and requirements may be changed from time to time. For example,the NFL currently requires that a regulation football have a long axisthat measures 11 to 11¼ inches, a long circumference that measures 28 to28½ inches, and a short circumference that measures 21 to 21¼ inches.The NCAA currently requires that a regulation football have a long axisthat measures 10⅞ inches to 11 7/16 inches, a long circumference thatmeasures 27¾ inches to 28½ inches, and a short circumference thatmeasures 20¾ inches to 21¼ inches. Other agencies can have differentrequirements for the dimensions of a regulation football. Each of thevarious rules and regulations recognize variations in the dimensions ofthe football that are permitted between individual footballs that arestill considered to be regulation footballs within the rules orregulations. By constructing a football using the process describedherein, the amount of variation between individual footballs producedwith the required dimensions may be limited or minimized.

Referring again to FIG. 13, football 1300 includes four panel segments,including first panel segment 600, second panel segment 602, third panelsegment 604, and fourth panel segment 606, described above. Together,the outer panel portions of the respective panel segments of cover 1200form the exterior surface of football 1300. Additionally, a lace element1302 may be included as a functional component of football 1300, forexample to secure parts of adjacent panel segments of cover 1200 to oneanother. Lace element 1302 may also assist a user in correctlypositioning his or her hand to pass or grip football 1300. In addition,in some cases, lace element 1302 may be included to perform a decorativefunction for football 1300.

In various embodiments, lace element 1302 may be attached to cover 1200in any suitable conventional manner, depending on the materials selectedfor cover 1200 and lace element 1302. For example, cover 1200 and laceelement 1302 may both be made from leather and/or synthetic leather andlace element 1302 may be inserted into perforations in cover 1200. Insome embodiments, reinforcements may be included on the perforations incover 1200 to prevent lace element 1302 from tearing through cover 1200.In another example, cover 1200 may be rubber and lace element 1302 maybe polyvinyl chloride, rubber, silicone, or other thermoplasticelastomers. In some embodiments, an adhesive might be used to adherelace element 1302 to the outside of cover 1200.

FIGS. 14 and 15 illustrate cross-section views of football 1300 withinflatable bladder 1100 in a deflated or partially inflated condition(FIG. 14) and a fully inflated condition (FIG. 15). Referring now toFIG. 14, inflatable bladder 1100 is shown disposed within the interiorof football 1300 surrounded by cover 1200. In this embodiment,inflatable bladder 1100 is in a deflated or partially inflated conditionand is being filled with air from an air pump 1400 via an air valve (notshown) disposed on cover 1200 that is in communication with inflatablebladder 1100.

In some embodiments, when inflatable bladder 1100 is in a deflated orpartially inflated condition, the outer panel portion and the innerpanel portion of each panel segment may be disposed apart from eachother. In an exemplary embodiment, the peripheral edges of the largerouter panel portion are joined along the peripheral edges of the smallerinner panel portion, causing the exterior surface of the outer panelportion to bulge outwards, as described above in reference to firstpanel segment 600. In this embodiment, first outer panel portion 200 isdisposed a fourth distance D4 from first inner panel portion 210. Insome embodiments, fourth distance D4 may be equal to or slightly smallerthan the difference between first width W1 and second width W2. In somecases, fourth distance D4 may be from 2 mm to 8 mm. In one embodiment,fourth distance D4 may be approximately 4 mm. In other cases, fourthdistance D4 may be less than 2 mm or may be more than 8 mm.

In an exemplary embodiment, each of the peripheral edges of first outerpanel portion 200 and first inner panel portion 210 forming first panelsegment 600 are joined with stitching to each other, as well as therespective peripheral edges of the adjacent panel segment, along seams.In this embodiment, peripheral edge 506 of first outer panel portion 200is joined with stitching to peripheral edge 302 of first outer panelportion 210 to the respective peripheral edges of the panel portions ofsecond panel segment 602 along seam 1202 and to the respectiveperipheral edges of the panel portions of third panel segment 604 alongseam 1204. Each of the panel segments, including second panel segment602, third panel segment 604, and fourth panel segment 606 may have acorrespondingly similar structure and be joined with stitching in asimilar manner as first panel segment 600.

As shown in FIG. 14, when air from air pump 1400 begins to inflateinflatable bladder 1100, the air pushes the inner panel portions,including first inner panel portion 210, towards the opposite outerpanel portion, including first outer panel portion 200. As inflatablebladder 1100 approaches the fully inflated condition, the inner panelportions will become pushed closer to and/or contact with, the outerpanel portions. For example, first inner panel portion 210 may be pushedtowards first inner panel portion 200, thereby reducing fourth distanceD4 separating the panel portions to substantially zero when inflatablebladder 1100 reaches a fully inflated condition.

FIG. 15 illustrates inflatable bladder 1100 in a fully inflatedcondition and in contact with cover 1200 disposed within the interior offootball 1300. In an exemplary embodiment, when inflatable bladder 1100is in the fully inflated condition, inflatable bladder 1100 will pressagainst each of the inner panel portions of the panel segments disposedabout the inside of cover 1200, including first panel segment 600,second panel segment 602, third panel segment 604, and fourth panelsegment 606. The pressure from inflatable bladder 1100 against the innerpanel portions causes the top surface of each inner panel portion to bepushed up against the interior surface of the corresponding outer panelportion. For example, with regard to first panel segment 600, the topsurface of first inner panel portion 210 is pressed up against andabutting the interior surface of first outer panel portion 200.

In some embodiments, due to the difference in the respective sizes ofthe inner panel portions and the outer panel portions, the inner panelportions may be pushed by inflatable bladder 1100 to fit flush againstthe outer panel portions. Because the inner circumference of football1300 is slightly smaller than an outer circumference of football 1300,the larger size of the outer panel portions and the smaller size of theinner panel portions allows the overall stretching of cover 1200 to beminimized or reduced.

For example, as shown in FIG. 15, outer circumferential distance C1 offirst outer panel portion 200 on first panel segment 600 is slightlylarger than inner circumferential distance C2 of first inner panelportion 210 on first panel segment 600. In some embodiments, outercircumferential distance C1 may be approximately equal to first width W1of first outer panel portion 200 less the distance corresponding to thestitched peripheral edge 506 along seam 1202 and seam 1204. Similarly,inner circumferential distance C2 may be approximately equal to secondwidth W2 of first inner panel portion 210 less the distancecorresponding to the stitched peripheral edge 302 along seam 1202 andseam 1204. Accordingly, when inflatable bladder 1100 is in a fullyinflated condition, the larger size of the outer panel portions reducesthe need for the outer panel portions to stretch to accommodateinflatable bladder 1100 in the fully inflated condition. With thisarrangement, the outer panel portions forming cover 1200 are subject toless variations in size caused by differences in stretch properties ofthe outer layer material 100 used to make first outer panel portion 200,as well as each other outer panel portion. As a result, the amount ofvariation between individual footballs produced within the tolerances ofthe dimensions required by different leagues or agencies may be limitedor minimized. In addition, in embodiments where the outer layer material100 includes a pebbled or textured surface, the reduced amount ofstretch applied to the outer panel portions may substantially maintainthe quality of the pebbled or textured surface so that grippability ofthe constructed football is improved.

The process of constructing an inflatable game ball using panel portionshaving different sizes has been described above in reference toconstructing a football. However, substantially similar principles maybe applied to the construction of any inflatable game ball. Accordingly,FIGS. 16 through 18 illustrate a process of constructing an inflatablegame ball in the form of a soccer ball made using the exemplary processdescribed above with reference to FIGS. 1 through 15. Similar principlesalso may be applied to the construction of other inflatable game balls,including basketballs, volleyballs, and other game balls having a coverand inflatable bladder.

In some embodiments, an inflatable game ball having multiple shapes ofpanel segments may be constructed with one or more of the panels havingdifferent sizes according to the process described above. In anexemplary embodiment, an inflatable game ball in the form of a soccerball may be constructed using panel segments that have at least twodifferent shapes. Referring now to FIG. 16, in some embodiments, a coverfor a soccer ball may be constructed with at least two different shapedpanel segments, including a first shape that is hexagonal and a secondshape that is pentagonal. In this embodiment, hexagonal shaped panelportions include a first hexagonal outer panel portion 1600 and a firsthexagonal inner panel portion 1610. Similarly, pentagonal shaped panelportions include a first pentagonal outer panel portion 1620 and a firstpentagonal inner panel portion 1630.

In an exemplary embodiment, each of first hexagonal outer panel portion1600 and first pentagonal outer panel portion 1620 may be cut or removedfrom an outer layer material that includes any suitable materialsdisclosed above for outer layer material 100. In one embodiment, theouter layer material used to form first hexagonal outer panel portion1600 and first pentagonal outer panel portion 1620 may be a natural orsynthetic leather material. In another embodiment, the outer layermaterial may include felt, wool, or similar materials suitable forindoor soccer ball construction. Similarly, each of first hexagonalinner panel portion 1610 and first pentagonal inner panel portion 1630may be cut or removed from an inner layer material that includes anysuitable materials disclosed above for inner layer material 110. In oneembodiment, the inner layer material used to form first hexagonal innerpanel portion 1610 and first pentagonal inner panel portion 1630 may beone or more of a polyester, nylon, or cotton fabric.

According to the principles of the construction process describedherein, each of the inner layer panel portions may have a substantiallysimilar shape as the outer layer panel portions, but may be a differentsize. In an exemplary embodiment, the inner layer panel portions may besmaller than the respective outer layer panel portions. As shown in FIG.16, first hexagonal outer panel portion 1600 may be associated with asize defined by a first radius R1 from a centerpoint to each of thevertices of the hexagon. Simiarly, first hexagonal inner panel portion1610 may be associated with a size defined by a second radius R2 from acenterpoint to each of the vertices of the hexagon. In an exemplaryembodiment, first radius R1 may be larger than second radius R2 suchthat first hexagonal inner panel portion 1610 is smaller than firsthexagonal outer panel portion 1600.

In one embodiment, the pentagonal shaped panel portions may have asimilar construction. As shown in FIG. 16, first pentagonal outer panelportion 1620 may be associated with a size defined by a third radius R3from a centerpoint to each of the vertices of the pentagon. Simiarly,first pentagonal inner panel portion 1630 may be associated with a sizedefined by a fourth radius R4 from a centerpoint to each of the verticesof the pentagon. In an exemplary embodiment, third radius R3 may belarger than fourth radius R4 such that first pentagonal inner panelportion 1630 is smaller than first pentagonal outer panel portion 1620.

In some cases, the differences in size between each of the panel layerportions may be substantially uniform around the entire perimeter of therespective hexagonal shaped panel layer portions and/or pentagonalshaped panel layer portions. In other cases, the differences in sizebetween each of the panel layer portions may vary along differentportions of the perimeter of the panel layer portions, similar to thepanel layer portions described above in reference to FIG. 3B. In stillother cases, a combination of uniformly different sizes and varyingdifferent sizes of panel layer portions may be used for various panelsegments used to form the cover of the soccer ball. With thisarrangement, the amount of variation or reduction in stretch of thecover of the soccer ball may be controlled to different degrees atspecific portions of the cover.

In some embodiments, panel segments used to construct a cover for asoccer ball may be formed using a substantially similar process asdescribed in FIGS. 4 through 7 above. In other embodiments, one or morealignment guides may be used in a substantially similar manner asdescribed in FIGS. 9 and 10.

FIG. 17 illustrates an exemplary embodiment of forming a first hexagonalpanel segment 1700 by joining first hexagonal outer panel portion 1600and first hexagonal inner panel portion 1610 along their respectiveperipheral edges. As shown in FIG. 17, each of the vertices of firsthexagonal outer panel portion 1600 are aligned with and joined to eachof the vertices of first hexagonal inner panel portion 1610 and thepanel portions are joined along the perimeter of their respectiveperipheral edges between the vertices. With this configuration, thesmaller size of first hexagonal inner panel portion 1610 causes firsthexagonal outer panel portion 1600 to bulge outward causing the exteriorsurface to have a substantially convex surface.

FIG. 17 also illustrates an exemplary embodiment of forming a firstpentagonal panel segment 1702 by joining first pentagonal outer panelportion 1620 and first pentagonal inner panel portion 1630 along theirrespective peripheral edges. In this embodiment, each of the vertices offirst pentagonal outer panel portion 1620 are aligned with and joined toeach of the vertices of first pentagonal inner panel portion 1630 andthe panel portions are joined along the perimeter of their respectiveperipheral edges between the vertices. With this configuration, thesmaller size of first pentagonal inner panel portion 1630 causes firstpentagonal outer panel portion 1620 to bulge outward causing theexterior surface to have a substantially convex surface.

In an exemplary embodiment, the peripheral edges of the respective panelportions of first hexagonal panel segment 1700 and/or first pentagonalpanel segment 1702 may be joined using adhesive or any other suitableattachment mechanism described above in regards to first panel segment600.

In some embodiments, a cover for an inflatable game ball in the form ofa soccer ball may be formed by attaching multiple hexagonal shaped panelsegments and pentagonal shaped panel segments in a predeterminedtruncated icosahedron shape. In various embodiments, the arrangement ofindividual panel segments of different shapes used to form the cover mayvary depending on the type of soccer ball being constructed. Forexample, a cover for a 32-panel soccer ball may include 20 hexagonalshaped panel segments and 12 pentagonal shaped panel segments. Othercover panel arrangements that may be used to construct a soccer ballinclude an 18-panel and a 26-panel construction. In still otherembodiments, different cover panel arrangements for inflatable gameballs using a larger or smaller number of panel segments may beprovided.

Referring now to FIG. 18, a soccer ball 1800 may be formed with a coverhaving a 32-panel construction. In an exemplary embodiment, one or moreof the panel segments forming the cover of soccer ball 1800 may includefirst hexagonal panel segment 1700 and/or first pentagonal panel segment1702 made using the process described herein. In this embodiment, firstpentagonal panel segment 1702 may be surrounded by and attached to fivesubstantially similar panel segments as first hexagonal panel segment1700. Similar groupings of substantially similar panel segments mayextend around soccer ball 1800 to form the cover. Each of the panelsegments may be attached to adjacent panel segments using stitching,bonding, adhesive, or any other suitable attachment mechanisms describedherein or known in the art. With this arrangement, the outer panelportions of each panel segment forming the cover of soccer ball 1800 aresubject to less variation in size caused by differences in stretchproperties of the outer layer material used to make the outer panelportions. As a result, the amount of variation between individual soccerballs produced within the tolerances of the dimensions required bydifferent leagues or agencies may be limited or minimized.

Additionally, in some embodiments, panel segments using the processdescribed herein may be combined with panel segments made usingconventional construction processes. With this arrangement, someportions of an inflatable game ball may be provided with tighterconstruction tolerances and less variation in stretch properties, whileother portions including the convention panel segments may be allowed tovary and stretch in a conventional manner.

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. Accordingly, the invention is not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

What is claimed is:
 1. A method of constructing an inflatable game ball,the method comprising: removing a plurality of outer panel portions froma first material, each of the outer panel portions having a first shapeand a first size; removing a plurality of inner panel portions from asecond material, each of the inner panel portions having the first shapeand a second size, the second size being smaller than the first size;joining the plurality of outer panel portions to the plurality of innerpanel portions along peripheral edges to form a plurality of panelsegments, each panel segment having a peripheral edge of one of theplurality of outer panel portions that is aligned with the peripheraledge of one of the plurality of inner panel portions; and attaching theplurality of panel segments together along the aligned peripheral edgesto form a cover of the inflatable game ball.
 2. The method according toclaim 1, wherein the first size is associated with a first length in alongitudinal direction along a major axis of each one of the outer panelportions and a first width in a lateral direction along a minor axis ofeach one of the outer panel portions; wherein the second size isassociated with a second length in the longitudinal direction along amajor axis of each one of the inner panel portions and a second width inthe lateral direction along a minor axis of each one of the inner panelportions; and wherein the second length is smaller than the first lengthand the second width is smaller than the first width.
 3. The methodaccording to claim 2, wherein a difference between the first length andthe second length is substantially equal to a difference between thefirst width and the second width.
 4. The method according to claim 2,wherein a difference between the first length and the second length issmaller than a difference between the first width and the second width.5. The method according to claim 1, wherein the step of joining theplurality of outer panel portions to the plurality of inner panelportions includes forming a concave surface on each outer panel portionthat bulges outwards from each inner panel portion.
 6. The methodaccording to claim 5, wherein the concave surface is disposed a firstdistance apart from the inner panel portion.
 7. The method according toclaim 6, wherein the first distance is approximately equal to adifference between the first size and the second size.
 8. The methodaccording to claim 1, further comprising: associating an inflatablebladder in a deflated condition within an interior of the cover; andinflating the inflatable bladder to a fully inflated condition.
 9. Themethod according to claim 8, wherein when the inflatable bladder is inthe deflated condition, an interior surface of the outer panel portionsis separated a first distance apart from a top surface of the innerpanel portions; and wherein when the inflatable bladder is in the fullyinflated condition, the interior surface of the outer panel portions isin contact with the top surface of the inner panel portions.
 10. Themethod according to claim 1, wherein the step of joining comprisesapplying adhesive along at least one of the peripheral edge of the firstinner panel portion and the peripheral edge of the first outer panelportion.
 11. A method of constructing an inflatable game ball, themethod comprising: providing a first outer panel portion removed from afirst material, the first outer panel portion having a first shape and afirst size, providing a first inner panel portion removed from a secondmaterial, the first inner panel portion having the first shape and asecond size, the second size being smaller than the first size;providing an alignment guide having the first shape and associated withan interior dimension that is substantially similar to the second size;placing the first inner panel portion into the interior of the alignmentguide such that a peripheral edge of the first inner panel portion isadjacent to an inner surface of the alignment guide; placing the firstouter panel portion into the interior of the alignment guide such that aperipheral edge of the first outer panel portion is disposed against theinner surface of the alignment guide; joining the first inner panelportion to the first outer panel portion along peripheral edges to forma panel segment, the panel segment having the peripheral edge of thefirst outer panel portion aligned with the peripheral edge of the firstinner panel portion; and attaching together a plurality of panelsegments along the aligned peripheral edges to form a cover of theinflatable game ball.
 12. The method according to claim 11, wherein thefirst size is associated with a first length in a longitudinal directionalong a major axis of the first outer panel portion and a first width ina lateral direction along a minor axis of the first outer panel portion;wherein the second size is associated with a second length in thelongitudinal direction along a major axis of the first inner panelportion and a second width in the lateral direction along a minor axisof the first inner panel portion; and wherein the second length issmaller than the first length and the second width is smaller than thefirst width.
 13. The method according to claim 11, wherein the step ofjoining comprises applying adhesive along at least one of the peripheraledge of the first inner panel portion and the peripheral edge of thefirst outer panel portion; and wherein the adhesive is configured totemporarily align the peripheral edge of the first outer panel portionand the peripheral edge of the first inner panel portion until the stepof attaching.
 14. The method according to claim 11, wherein the firstmaterial includes leather and the second material includes a flexiblefabric.
 15. The method according to claim 11, wherein the step ofjoining the first outer panel portion to the first inner panel portionincludes forming a concave surface on the first outer panel portion thatbulges outwards from the first inner panel portion.
 16. The methodaccording to claim 15, wherein the concave surface is disposed a firstdistance apart from the first inner panel portion.
 17. The methodaccording to claim 11, further comprising associating an inflatablebladder in a deflated condition within an interior of the cover; whereinwhen the inflatable bladder is in the deflated condition, an interiorsurface of the first outer panel portion is separated a first distanceapart from a top surface of the first inner panel portion; and whereinwhen the inflatable bladder is in a fully inflated condition, theinterior surface of the first outer panel portion is in contact with thetop surface of the first inner panel portion.
 18. An inflatable gameball comprising: a cover, the cover comprising a plurality of panelsegments attached along peripheral edges; and an inflatable bladderdisposed within an interior of the cover, the inflatable bladder beingassociated with a deflated condition and a fully inflated condition;wherein each panel segment comprises: a first outer panel portion havinga first shape and a first size; a first inner panel portion having thefirst shape and a second size, the second size being smaller than thefirst size; and wherein the first outer panel portion is joined with thefirst inner panel portion such that a peripheral edge of the first outerpanel portion is aligned with a peripheral edge of the first inner panelportion.
 19. The inflatable game ball according to claim 18, wherein thefirst size is associated with a first length in a longitudinal directionalong a major axis of the first outer panel portion and a first width ina lateral direction along a minor axis of the first outer panel portion;wherein the second size is associated with a second length in thelongitudinal direction along a major axis of the first inner panelportion and a second width in the lateral direction along a minor axisof the first inner panel portion; and wherein the second length issmaller than the first length and the second width is smaller than thefirst width.
 20. The inflatable game ball according to claim 19, whereinan outer circumference of each of the panel segments of the cover isapproximately equal to the first width of the first outer panel portionless a distance associated with a portion of the peripheral edge joinedto the first inner panel portion.
 21. The inflatable game ball accordingto claim 19, wherein an inner circumference of each of the panelsegments of the cover is approximately equal to the second width of thefirst inner panel portion less a distance associated with a portion ofthe peripheral edge joined to the first outer panel portion.
 22. Theinflatable game ball according to claim 18, wherein an interior surfaceof the first outer panel portion is separated a first distance apartfrom a top surface of the first inner panel portion with the inflatablebladder in the deflated condition; and wherein the interior surface ofthe first outer panel portion is in contact with the top surface of thefirst inner panel portion with the inflatable bladder in the fullyinflated condition.